Seamless gel cushion

Abstract

A gel cushion, and a method of manufacturing same, in accordance with the present invention generally includes the steps of cooling a mold to a selected temperature, disposing a porous stretchable fabric over the cooled mold, depositing a volume of gelable liquid within the mold such that the cooled mold enables pores of the fabric to fill with gel without penetration therethrough, applying a vacuum between the fabric and the mold, allowing the gel to set and solidify and removing the solidified gel having the fabric fixed thereto in order to obtain the gel cushion. Another embodiment of the invention includes the step of filling a second matching mold and bonding the two volumes of gelable liquid together in order to make a fabric enclosed gel cushion. Yet another embodiment of the invention includes the step of depositing air filled bags or balloons on the coated fabric prior to injecting the additional gel in order to make a gel cushion having voids therein.

What is claimed is: 
     
       1. A gel cushion comprising: a stretchable fabric having a selected contour; and   gel means for supporting the stretchable fabric in the selected contour, said gel means produced by:   cooling a mold having the selected contour to a selected temperature,   disposing the stretchable fabric over the cooled mold,   depositing a volume of gelable liquid into the mold onto an exposed side of the stretchable fabric, said gelable liquid entering pores of the stretchable fabric and said cooled mold preventing penetration of the gelable liquid through the fabric by causing gelation of the gelable liquid within the pores,   applying a vacuum between the fabric and the mold in order to cause the fabric to be stretched and vacuum formed, the application of vacuum being performed during the step of depositing the volume of gelable liquid in order to maintain a surface contour of the gel cushion by causing expansion of the pores and filling of the exposed pores with the gelable liquid;   allowing a remainder of the volume of gelable liquid to gelate in the mold, and   removing the gel and the vacuum formed fabric fixed thereto from the mold.   
     
     
       2. The gel cushion according to claim 1 further comprising tray means for supporting the gel cushion in a rigid fashion. 
     
     
       3. The gel cushion according to claim 1 wherein the gel means does not penetrate the fabric. 
     
     
       4. A gel cushion comprising: a stretchable fabric having a selected contour, said stretchable fabric having expanded pores of varying expansion over curved portions of the stretchable fabric; and   gel means for supporting the fabric in the selected contour and for maintaining the varying expansion of the pores, said gel means produced by:   depositing a volume of gelable liquid onto an exposed side of the fabric, said gelable liquid entering the pores of the fabric;   preventing penetration of the gelable liquid through the fabric by cooling the mold in order to cause gelation of the gelable liquid within said pores;   applying a vacuum between the fabric and the mold in order to cause the fabric to be stretched and vacuum formed, the application of vacuum being performed during the step of depositing the volume of gelable liquid in order to maintain a surface contour of the gel cushion by causing expansion of the pores and filling of the exposed pores with the gelable liquid;   allowing a remainder of the volume of gelable liquid to gelate in the mold; and   removing the gel and the vacuum formed fabric fixed thereto form the mold in order to obtain a gel cushion.   
     
     
       5. The gel cushion according to claim 4 wherein the gel means does not penetrate the fabric. 
     
     
       6. The gel cushion according to claim 4 further comprising tray means for supporting the gel cushion in a rigid fashion. 
     
     
       7. A gel cushion exercising device comprising: a first porous stretchable fabric;   a second porous stretchable fabric; and   gel means, enclosed by the stretchable fabrics, said gel means produced by:   cooling a first mold and a second mold to a selected temperature,   disposing the first stretchable fabric and the second stretchable fabric over the first cooled mold and the second cooled mold respectively,   depositing a first volume of gelable liquid and a second volume of the gelable liquid into the molds onto exposed sides of the first and second stretchable fabrics respectively, said gelable liquid entering pores of the stretchable fabrics and said cooled molds preventing penetration of the gelable liquid through the fabrics by causing gelation of the gelable liquid within said pores,   applying a vacuum between the stretchable fabrics and the molds in order to cause the fabrics to be stretched and vacuum formed, the application of vacuum being performed during the step of depositing the volume of gelable liquid in order to maintain a surface contour of the gel cushion by causing expansion of the pores and filling of the expanded pores with the gelable liquid;   allowing a remainder of the volumes of gelable liquid to gelate in the molds,   bonding the volumes of gelable liquid together by causing contact therebetween during the step of   allowing the remainder of the volumes to gelate, and   removing the gel, having the fabrics enclosing and fixed thereto, from the molds.   
     
     
       8. The gel cushion exercising device according to claim 7 wherein the selected temperature of the cooled mold is between about 40° F. and 50° F. 
     
     
       9. The gel cushion exercising device according to claim 8 wherein the gelable liquid is deposited at a temperature of between about 300° F. and about 500° F. 
     
     
       10. The gel cushion according to claim 7 wherein the gel means does not penetrate the fabric. 
     
     
       11. The gel cushion according to claim 7 further comprising tray means for supporting the gel cushion in a rigid fashion.